Method of making cemented pile carpet



Nov. 27, 1945. P, FARls T L 2,389,657

METHOD OF MAKING CEMENTED FILE CARPET Original Filed Jan. 4, 1944 5Sheets-Sheet 1 INVENTORS JHAROLD P FARIS ATTORNEYS JOHN ZJVHITE Nov. 27,1945. H. P. FARIS ETAL 2,389,557

METHOD OF MAKING CEMENTED PILE CARPET Original Filed Jan. 4, 1944 5Sheets-Sheet 2 INVENTORS HAROLD P. FARIS 2 BY JOHNE.WHITE ATTORNEYSNov.- 27, 1945. H. P. FARIS ET AL 2,389,657

METHOD OF MAKING CEMENTED PILE CARPET I Original Filed Jan, 4, 1944 5Sheets-Sheet 3 IN V EN TORs HAROLD P.FARIS BY JOHN gwnmz M M W ATTORNEYS Nov. 27, 1945. H. P. FARIS ETAL 2,389,657

METHOD OF MAKING CEMENTED PILE CARPET Original Filed Jan. 4, 1944 5Sheets-Sheet 4 INVENTORS HAROLD PFARIS JOHN E.WHITE' ATTORNEYS H. P.FARIS ET AL 2,389,657

METHOD OF MAKINGCEMENTED FILE CARPET Original Filed Jan. 4, 1944 5Sheets-Sheet 5 INVENTORS HAROLD PQFARIS JOHN E.WH|TE ATTORNEYS PatentedNov. 27, 1945 METHOD OF MAKING CEMENTED PILE CARPET Harold P. Faris,Philadelphia, Pa., and John E. White, Trenton, N. J., assignors toNational Automotive Fibres, Ina, Detroit, Mich., a corporation ofDelaware Original application July 20, 1942, Serial No.

451,626, now Patent No. 2,338,499, dated January 4, 1944. Divided andthis application July 6, 1943, Serial No. 493,666

3 Claims. (Cl. 11733) This invention relates generally to themanufacture of rugs, carpets and the like and constitutes a division ofour application filed July 20, 1942, bearing Serial No. 451,626, whichissued January 4, 1944 as Patent 2,338,499.

More specifically, the present invention relates to the manufacture ofcemented pile carpet wherein the pile surface thereof is composed of amultiplicity of individual upstanding fibers that simulate ordinarywoven pile in appearance.

Preferably the carpet is made by depositing the individual fibers onto acement or adhesive covered base while the latter is being vibrated,however in the present instance the invention is characterized by (1)successive deposits of different types or grades of fibers onto theadhesively covered base, (2) the uniform feeding and uniform depositionof the fibers, (3) the removal from the base of loose or excess fibersbefore successive deposits are made, (4) the uniformity in weight andlength of the fibers initially deposited, (5) a more perfect initialformation of the fibers, (6) the use of a longer pile material thanordinarily employed, ('7) the positive breaking up and carding of theflock into individual fibers, (8) the controlled supply of fibers fromthe feed units, and (9) the improved or more equalized vibrating meansfor the base to obtain a more uniform and deeper penetration of thefibers into the adheslve or cement covering on the base.

Thus, one of the essential objects of the present invention is toprovide an improved method of making cemented pile carpet whereby acarpet having a better pile surface is obtained.

Another object is to provide an efficient method which may beexpeditiously employed for mak ing quickly and on a large scale orproduction basis cemented pile carpet and the like having improvedcharacteristics.

Other objects, advantages and novel details of construction of thisinvention will be made more apparent as this description proceeds,especially when considered in connection with the accompanying drawings,wherein:

Figure 1 is a side elevational view of a machine embodying our inventionfor making the carpet, with parts broken away and in section;

Figure 2 is a vertical sectional view taken on line 2-2 of Figure 3;

Figure 2A is a sectional view taken on the line 2A2A of Figure 2;

Figure 3 is a rear end view of the assembly illustrated in Figure 2;

ure 4 is a sectional view taken substantially on the line 4-4 of Figure3;

Figure 5 is a top plan view of the structure illustrated in Figure 2;

Figure 6 is an enlarged elevational view of the first feed unit, withparts broken away and in section;

Figure 7 is a fragmentary side elevation of the. rear end of the machineillustrated in Figure 1 and showing a slight modification;

Figure 8 is a side elevation of the first feed unit as illustrated inFigure 1 but showing a modified agitator assembly in combinationtherewith;

Figure 9 is a vertical sectional view through the material X beforebeing flocked;

Figure 10 is a vertical sectional view through a carpet made inaccordance with my invention.

Referring now to the drawings, A and B respectively, are feed rolls ofcalendered material to be flocked, C is a vertical series of tensionrolls for said material, D is an adhesive doctor knife or cementspreader knife, E, F and G respectively, are vibrator or beaterassemblies for the material, H is a roll for pulling material from thefeed rolls A and B over the vibrator assemblies E, F and G'respectively,J, K and L respectively, are flock feed units, and M, N and 0respectively, are suction nozzles for cleaning off or removing loose orexcess fibers from the adhesive or cement upon said material.

As shown, the rolls A and B are spaced vertically apart and are carriedby a suitable frame It at one end of the machine. Preferably thematerial on the lower roll A is used first and then the material on theupper roll B is used. If desired, the lead end of the material on theupper roll B may be spliced or otherwise secured to the tail end of thematerial on the lower roll A to provide a continuous operation. In eachinstance. the material X may be burlap I, woven cloth or a syntheticsheet or paper having the proper tensile strength, or a smooth sheet ofany other suitable material calendered to uncured sponge rubber 8, orsome other suitable substance having resilient qualities. Such materialis drawn from the rolls A and B around the tension rolls C and over thevibrator or heater assemblies E, F and G respectively, by the pullerroll H at the other end of the machine.

The tension rolls C may be any suitable construction and are arranged tokeep the material X firm and unde tension as it passes through themachine. Suitable means (not shown) may be employed for driving thetension rolls C at approximately five (5) per cent slower speed than thepuller roll H.

After leaving the tension rolls C the material having the rubber sidethereof lowermost passes over idler rolls I and I2 respectively, ontothe first agitator or beater assembly E. However, before it reaches theassembly E, the upper surface of the material is covered substantiallywith a layer 9 of suitable adhesive substance or cement which may be arubber cement or some plastic substance that is impervious to gasolineand cleaning fluids. For this purpose the adhesive doctor blade orcement spreader knife D is mounted over the idler roll I I and may beprovided with a suitable adjustment, as desired. Any suitable means (notshown) may be applied for supplying an adhesive or cement to the doctorblade.

The first agitator or beater assembly E has an endless conveyor l3, anda battery i4 of rotating beaters l5. Preferably the conveyor I 3comprises an endless apron for supporting the material X over thebeaters l5 and is driven at substantially the same speed as the pullerroll H. The beaters l5 may be any suitable construction but arepreferably six-sided bars that extend across and engage the underside ofthe top portion or flight of the endless conveyor 13 at spaced pointslongitudinally thereof. Any suitable means such as the motor driven beltl6 which engages pulley wheels I! at one end of the bars l5 may be usedto rotate said bars, while any suitable means such as the crank l8,pitman l8a and lever l9, may be used to slide the rotating bars l5 backand forth lengthwise of the conveyor l3 to equalize as far as possiblethe vibration wave and obtain a better and more uniform penetration ofthe fibers in the adhesive substance or cement 9 upon the material Xbeing agitated. In fact, the

posite directions. Moreover, the bars are journaled in bearings and 2|respectively, clamped upon rails 22 and 23 respectively, slidablyengaging suitable guide blocks 24 and 25 respectively, carried by thesupporting frame 26. One of these bearings 20 is rigid with the lever l9so that the bars l5 will move back and forth in unison.

If desired, two heaters 21 and 28 respectively, of six-sided formationmay be mounted for rotary movement only in front and in rearrespectlvely the battery H of agitators and may be driven by the belt l6constituting the drivin means for the beaters IS.

The second a itator assembly F is between the first assembly E and thepuller roll H and preferably comprises a battery 29 of beaters 30 ofsixsided formation that are mounted for rotary movement only and haveagitating engagement with the underside of an endless conveyo 3| for thematerial X.

The third a itator assembly G is between the second assembly F and thepuller roll H and preferably consists of two spaced electric vibratorsor electromagnetic settling plates 32 and 33 respectively, which engagedirectly and form vibrating supports for the underside of the material Xafter it leaves the conveyor 3| for the puller roll 1!.

The puller roll H may be any suitable construction and may be driven byany suitable means. Preferably the periphery of said roll is providedwith teeth 34 or'other suitatble means for positively engaging thematerial to pull it forward through the machine as desired.

The first flock feed unit J is spaced above t e first agitator assemblyE and handles only selected flock. In fact, the flock used at this pointI is substantially uniform in weight and length so as to be wellbalanced and, therefore, may be considered to have only grade A typefibers. Preferably flock of this type in bulk form is dumped into asuitable storage bin 35' from which it is conducted by a screw conveyor(not shown) within a suitable duct 36 to the unit J where it ispositively broken up and carded into individual fibers before beingdischarged onto the adhesive or cement covered material advancing overthe agitator assembly E.

In the present instance, the positiv breaking up and carding action isperformed by a group of co-operating rolls 31, 38, 39, 40, 4| and 42respectively, that have at their peripheries suitable carding wires 43for engagement with the flock. A feed roll 44 at the discharge end ofthe duct 36 controls the supply of the flock from the duct to thecarding rolls. while a fancy roll 45 at the other side of the group ofcarding rolls controls the discharge of individual fibers from saidgroup onto the adhesive or cement covered material X. Any suitable means(not shown) may be employed for rotating the rolls mentioned. In fact,the feed and quantity of flock transferred from the duct 36 to thecarding rolls is controlled by the speed of rotation of the feed roll44. The carding rolls 3! to 42 inclusive rotate in predetermineddirections as indicated by the respective arrows thereon and atpredetermined speeds to accomplish the positive breaking up and cardingof the flock into individual fibers and to advance such fibers instraightened condition to the fancy roll 45. As shown, the fancy roll 45is provided with longer carding wires 46 and rotates at a faster speedso that it can throw the individual fibers downwardly in substantially auniform stream to the cement or adhesive covered material X where mostof them are imbedded endwise in the cement or adhesive substance thereonas the material is vibrated.

Thus, the discharge of the fibers from the feed unit J and-thedeposition thereof on the cement or adhesive covered material X iscontrolled and substantially uniform and tends toprovide a better andmore uniform initial formation thereof in the adhesive substance orcement on the material X as it is agitated. The positive breaking up andcarding action precludes the fibers falling in gobs, balls or othersubstantially solid formations onto the cement or adhesive coveredmaterial X and permits longer fibers to be used to make a deeper pile onsuch material. Moreover, it is unnecessary, due to this positivebreaking up and carding action, to initially sift or dryclean the flockas heretofore, as it is not now necessary to have the fibers bone drybefore being used. Instead, it will suflice if the flock is merelysubjected to an ordinary inexpensive scouring to remove traces of greaseand dirt.

Preferably therolls aforesaid of the feed unit J are within a metal hoodor casing 41 that has an inlet opening 48 at the discharge end of theduct 36 and is provided at the fancy roll 46 with an outlet-opening 49from opposite sides of which suitable sheet metal panels 50 'and 5|incline downwardly in the form of an'inverted V toward the a itatorassembly E. Electric vibrators 52 and 53, respectively, of conventionaldesign are mounted upon the back of these panels 50 and SI to agitatethe same and thereby prevent the fibers discharged from the fancy roll46 sticking or adhering to the opposed faces of said panels.

assacsv The second flock feed unit K is spaced above the second agitatorassembly F and is preferably identical to the first feed unit J.However, a somewhat inferior grade of flock is preferably used in thisfeed unit. Such flock is selected as a secondary fill for the initialformation on the adhesive or cement covered material X to help build upa, solid pile on said material.

The third flock feed unit L is also spaced above the secondagitatorassembly F and preferably comprises a vertical chute provided atits lower discharging end with suitable carding rolls 6!! and Birespectively. The same grade of flock used in the second feed unit K ora more inferior grade of flock may be used in the third unit to make thefinal fill for the pile previously formed on the material X.

The suction nozzles M, N and respectively are preferably located atspaced points of the machine to clean off or remove loose or excessfibers from the adhesiv or cement covered material X after the fibershave been deposited thereon from the feed units J, K and L respectively.As shown, the first nozzle M is between the first and second feed unitsJ and K for cleaning up the material X after the initial deposit is madethereon and before the deposit from the second feed unit K is made; thesecond nozzle N is between the secand and third feed units K and L forcleaning up the material X after the second deposit and before thedeposit from the third feed unit is made; and the third suction nozzle 0is at the rear of the third feed unit L for making a final clean-up.Such nozzles M, N and 0 may be connected by suitable ducts to thestorage bins from ich the fiock for the respective feed units isobtained. Preferably the first nozzle M is connected to a duct 62 thatleads to th storage bin 35 for the first feed unit J and contains asuitable suction fan or blower 63 for drawing off-the material X andreturning to the first bin 35 any loose fibers that did not becomeimbedded in the cement or adhesive substance on said material afterbeing discharged from the first feed unit J. In this connection, theduct 62 has a branch 6Q that extends from the bottom of a trough 65located below the first agitator assembly E for receiving any fibersoverflowing the sides of the endless conveyor it. Thus, the fibers thatare discharged from the first feed unit J and fail to be imbedded in thecement or adhesive substance on the material X are returned to thestorage bin 35 for the first feed unit J to be used again.

Likewise, the second suction nozzle N is connected to a duct 66 thatleads to a second storage bin (not shown) for the second feed unit K andcontains a suction fan or blower 61 for drawing off the material X andreturning to the second bin mentioned any loose fibers that did notbecome imbedded in the cement or adhesive substance on the material Xafter being discharged from the second feed unit K.

The third suction nozzle 0 is connected to a duct 68 that leads to thethird feed unit L and that contains a suction fan or blower 69 fordrawing off the material X and returning to the third feed unit L anyloose fibers that did not become imbedded in the cement or adhesivesubstance on the material X after being discharged from the third feedunit L. However, in this instance, there is a branch duct that leadsfrom the duct 68 to the second bin mentioned, and there is also a supplyduct II that leads from the second bin mentioned to the duct 68 on theintake side .of

the blower 69. A suitable directional damper I2 may be provided at thejuncture of the ducts S8 and III to control the flow therethrough offibers from the blower 69.

Thus, with this arrangement, it will be apparent that provision has beenmade in the first instance for depositing one type of flock onto thematerial X, then cleaning the material X, then depositing another typeof flock onto said material, then again cleaning the material X, finallydepositing the same type of flock again onto the material X, and finallyagain cleaning the material X before completing the process. Hence, thesurface of the adhesive substance or cement on the material X is cleanin each instance before the flock is deposited thereon. Actually, eachsuccessive deposit of fibers may be accomplished without interference onthe material X with loose fibers that would form obstacles that wouldprevent the deposited fibers from becoming imbedded in the adhesivesubstance or cement on such material. As a result more of the fibersdeposited will become imbedded in the adhesive substance or cement toprovide a denser pile formation. Moreover, it will be apparent that thethree a tator assemblies E, F and G respectively are located at suchpoints relative to the feedunits J, K and L respectively, that thefibers imbedded in the adhesive substance or cement on the material Xwill sink farther and farther into such adhesive substance or cement asthe material advances over and is agitated by the respective assembliesE, F and G. In fact, by the time the fibers pass over the third andfinal agitator assembly G they will sink to a point near the bottom ofthe cement or adhesive substance on the material X, hence such'fiberswill not only be dense as aforesaid but will also be anchored firmly andsolidly as desired. As a result, a solid, wellanchored pile is providedon the material X.

If desired, some other means such as the cooperating rolls 8!! and 8|respectively may be employed instead of the electric vibrators 32 and 33after the pile has been formed as aforesaid on the material X to pushthe fibers of the pile down farther into the cement or adhesivesubstance on said material for better anchorage purposes. As shown, thelower roll M is an idler roll and engages the underside of the materialX, while the upper roll is a pressure roll and has suitable adjustingmeans 82. Preferably the periphery of at least the upper roll 80 iscovered with sponge rubber 83 or the like for engagement with the pileformed on the material X.

After the pile mentioned is formed, the material X provided with suchpile is advanced through an oven or other heating chamber (not shown)where the sponge rubber 8 on the underside of the material X is curedand where the adhesive substance or cement 9 in which the pile isanchored is dried or cured to provide the finished product.

In Figure 8 I have illustrated a slight modification whereinelectro-static equipment R is provided instead of the agitator assemblyE beneath the first feed unit J. As shown, an electrically chargedreciprocating screen of conventional design is supported between thefancy roll 45 and the endless conveyor i3 in position to receive thefibers discharged from the unit J, while an electrically chargedelectrode 9| is located immediately below the top flight portion of theendless conveyor as an agitator for the material X. Thus, theelectrically charged screen 90 causes the fibers to dance up and downand fall in a straightened condition into the adhesive substance orcement 9 on the material X, while the charged electrode 9| will vibratethe material X so that such fibers will be imbedded endwise in thecement or adhesive substance mentioned. Otherwise the construction andoperation of the parts illustrated in Figure 8 are the same as in Figure1.

In use, the material X from thefeed rolls A and B will be covered by thedoctor blade D with a suitable layer 9 of adhesive substance or cementwhich will receive successively three deposits of fibers from the feedunits J K and L respectively as the material is advanced over andvibrated successively by the three agitator assemblies E, F and Grespectively. The initial deposit from the feed unit J consists ofselected, well-balanced fibers of substantially uniform length andweight to provide a better and more uniform initial formation on thematerial X, while the second and third deposits may be of an inferiorgrade of fibers. The suction nozzles M, N and respectively willeffectively remove loose fibers from the adhesive substance or cement 9on said material to insure a clean surface for each successive depositof fibers. Hence, a denser formation of the fibers on the material X maybe obtained. The arrangement of the agitators E, F and G for thematerial X insures the proper anchorage of the fibers in the adhesivesubstance or cement 9 because successive vibrations cause such fibers tosink farther and farther into such adhesive substance or cement. Thus,the pile formed by the fibers on the material X will be denser andanchored better than heretofore.

What we claim as our invention is:

l. The method of making a cemented pile carpet, comprising the steps ofcovering advancing sheet material with an adhesive substance, projectinga batch of fibers onto the adhesive covering while vibrators are movedback and forth lengthwise of the underside of said material to cause asubstantial proportion of said fibers to imbed themselves substantiallyuniformly in said adhesive covering and thereby produce a substantiallyuniform initial pile formation, withdrawing loose and excess fibers fromsaid initial formation, again vibrating the advancing material to causethe fibers of the initial formation to be imbedded farther into thecovering and simultaneously proprojecting a second batch of fibers ontothe adhesive covering while the material is being vibrated again asaforesaid to cause a substantial proportion of the second batch offibers to be imbedded in the covering to make the initial formationdenser, withdrawing loose and excess fibers from the denser formationwhile the advancing material is vibrated again as aforesaid,continuing'the vibration of the advancing material to cause the fibersof the denser formation to be imbedded farther into the covering andsimultaneously projecting a third batch of fibers onto the adhesivecovering while the vibration of the material is continued to cause asubstantial proportion of the third batch of fibers to be imbedded inthe covering to complete the pile formation, withdrawing loose andexcess fibers from the complete formation, and again vibrating theadvancing material to cause the fibers of the complete formation to beimbedded farther into the adhesive covering.

2. The method of making a cemented pile carpet, comprising the steps ofadvancing a base material beneath an adhesive spreader and over threespaced groups of agitators so that such advancing base material will inturn be covered by adhesive from said spreader and thereaftersuccessively vibrated by said agitators, depositing carded fibers ontosaid adhesive covering as the base material passes over the first groupof agitators to produce an initial pile formation and simultaneouslymoving the agitators of the first group back and forth lengthwise ofsaid advancing material to substantially equalize the vibration of saidmaterial to thereby obtain a substantially uniform penetration of thefibers in the adhesive covering, sucking loose and excess fibers fromsaid initial pile formation as said base material advances from thefirst group to the second group of agitators, depositing more cardedfibers onto the adhesive covering as the base material advances over and'is vibrated by the second group of agitators to make the initial pileformation denser, sucking loose and excess fibers from said denser pileformation as said base material is being vibrated by the second group ofagitators, depositing additional fibers onto the adhesive covering asthe base material advances still farther over the second group ofagitators to complete the pile of fibers, and sucking loose and excessfibers from the complete pile of fibers before the advancing basematerial reaches the third group of agitators to be vibrated thereby.

3. The method of making a cemented pile carpet, comprising the steps ofadvancing a base material beneath an adhesive spreader and over threespaced groups of agitators so that such advancing base material will inturn be covered by adhesive from said spreader and thereaftersuccessively vibrated by said agitators, depositing fibers ofsubstantially uniform weight and length onto said adhesive covering asthe base material passes over the first group of agitators to produce aninitial pile formation and simultaneously sliding the agitators of thefirst group back and forth lengthwise of said advancing material tosubstantially equalize the vibration of said material to thereby obtaina substantially uniform penetration of the fibers in the adhesivecovering, sucking loose and excess fibers from said initial pileformation when said advancing base material is between the first groupand the second group of agitators, depositing more carded fibers ontothe adhesive covering as the base material advances over and is vibratedby the second group of agitators to make the initial pile formationdenser, sucking loose and excess fibers from said denser pile formationas said base material is being vibrated by the second group ofagitators, depositing additional fibers onto the adhesive covering asthe base material advances still farther over the second group ofagitators to complete the pile of fibers, and sucking loose and excessfibers from the complete pile of fibers before the advancing basematerial reaches the third group of agitators to be vibrated thereby.

HAROLD P. FARIS. JOHN E. WHITE.

